Reacted Conductive Gate Electrodes and Methods of Making the Same

ABSTRACT

A semiconductor device and a method for fabricating a semiconductor device involve a semiconductor layer that includes a first material and a second material. The first and second materials can be silicon and germanium. A contact of the device has a portion proximal to the semiconductor layer and a portion distal to the semiconductor layer. The distal portion includes the first material and the second material. A metal layer formed adjacent to the relaxed semiconductor layer and adjacent to the distal portion of the contact is simultaneously reacted with the relaxed semiconductor layer and with the distal portion of the contact to provide metallic contact material.

This application is a continuation of U.S. patent application Ser. No.14/697,337, filed on Apr. 27, 2015, entitled “Reacted Conductive GateElectrodes and Methods of Making the Same,” which is a continuation ofU.S. patent application Ser. No. 14/320,065, filed on Jun. 30, 2014,(now U.S. Pat. No. 9,048,167, issued on Jun. 2, 2015) entitled “ReactedConductive Gate Electrodes and Methods of Making the Same,” which is adivisional of U.S. patent application Ser. No. 13/342,589, filed on Jan.3, 2012, (now U.S. Pat. No. 8,785,315, issued on Jul. 22, 2014) entitled“Reacted Conductive Gate Electrodes and Methods of Making the Same,”which is a continuation of U.S. patent application Ser. No. 10/944,618,filed on Sep. 17, 2004, (now U.S. Pat. No. 8,129,821, issued on Mar. 6,2012) entitled “Reacted Conductive Gate Electrodes,” which is acontinuation of U.S. patent application Ser. No. 10/179,079, filed Jun.25, 2002, (now U.S. Pat. No. 6,982,474, issued on Jan. 3, 2006) entitled“Reacted Conductive Gate Electrodes,” the entire disclosures of theseapplications are incorporated by reference herein.

TECHNICAL FIELD

The invention generally relates to semiconductor devices, and, moreparticularly, to the fabrication and structure of contacts intransistors.

BACKGROUND INFORMATION

Continuous improvements in the fabrication and design of semiconductortransistors used in integrated circuit devices have permitted evergreater area densities of transistors. Development of materials andprocessing for interconnects and contacts plays a large role intransistor development.

Materials and processes for forming conductive contacts andinterconnects must accommodate, for example, dimensional requirements,processing temperatures, reliability needs and materials compatibility.Traditional aluminum-based interconnects have gradually given way tocopper interconnects for fine dimensions; cobalt silicide and othermetallic materials are gradually supplanting titanium silicide sourceand drain contacts and titanium silicide caps on doped polycrystallinesilicon gate contacts.

Another avenue for improvement in device performance involves the use ofnewer types of substrates as replacements for traditional siliconwafers. For example, wafers that have a silicon-germanium (SiGe) layercan provide improved channel layer performance in a strained-siliconlayer grown on the SiGe layer.

Mobility enhancements obtained from strained silicon, in combinationwith source-drain and gate silicidation techniques, provide theopportunity to increase speed, reduce power consumption, and provide thebasis of other advances in microelectronics, such as analog and digitaldevice integration.

The use of substrates that include a SiGe layer, however, can increasefabrication complexity relative to that for conventional siliconwafer-based devices. For example, formation of source and drain contactsthrough reaction of a metal layer, such as titanium or cobalt, with SiGein the substrate has preferred process conditions that are differentfrom silicide formation with relatively pure silicon.

SUMMARY OF THE INVENTION

The invention involves structures and fabrication methods forsemiconductor devices that preferably have semiconductor layersincluding two materials in both a substrate and in a gate contact. Theinvention provides simplified processing for semiconductor devices, aswell as improved semiconductor device structures that include compoundand/or alloyed semiconductors in both contacts and substrates. Theinvention provides for simultaneous reaction of a metal layer to formreacted material contacts in the substrate and a reacted material upperportion of a gate contact. The metal layer exhibits a similar reactionbehavior with the semiconductor layers in both the substrate and in theupper portion of the gate contact due to a similar composition ratio ofthe two materials in both semiconductor layers.

Preferred embodiments of the invention feature substrates and contactsthat include one or more semiconductor alloy layers of silicon andgermanium. Preferred embodiments include SiGe layers of similarcomposition in both a substrate and a contact; conductive portions areformed by simultaneously reacting the SiGe layers in the substrate andthe contact with a metal layer. Thus, for example, source and draincontacts in a substrate can be formed simultaneously with formation of aconductive upper (distal) portion of a gate contact having a portionthat includes the semiconductor alloy. In this way, some processingsteps are rendered unnecessary during basic device fabrication.

Simplified processing can be achieved in part because reaction of ametal layer with the substrate and with a semiconductor layer in a gatecontact need not be decoupled to accommodate, for example, SiGe in thesubstrate and polycrystalline silicon in the gate. Proper materialselection provides substrates and gate contacts that have similar oridentical silicide formation steps. Other benefits can arise, such aslower temperature processing for silicide formation.

In preferred embodiments, the invention features transistors thatinclude a gate electrode including SiGe in at least an upper portion ofa gate contact (i.e., electrode) and a strained-silicon channel layer ona relaxed SiGe layer in a substrate. By having SiGe in an upper portionof a gate electrode, the silicidation of gate and source-drain regionscan be performed in a single process. A lower portion of the gatecontact can have a different material composition, chosen to provide,for example, a desired electrical property and/or compatibility with agate dielectric material.

Thus, in a first aspect, the invention features a method for fabricatinga semiconductor device. The method includes provision of a semiconductorlayer that includes a first material and a second material. Thesemiconductor layer can be an alloy of two or more materials. The firstand second materials can be silicon and germanium.

The semiconductor layer can be or include a relaxed layer. The relaxedlayer can be part of a substrate having a portion, adjacent to therelaxed layer, with a lattice spacing mismatched to that of the relaxedlayer. For example, the relaxed layer can be grown on intermediatelayers that accommodate mismatch to a silicon wafer. As another example,the relaxed layer can reside on an oxide layer.

The method also includes the formation of a contact that has a portionproximal to the relaxed semiconductor layer and a portion distal to therelaxed semiconductor layer. The distal portion includes the firstmaterial and the second material. A metal layer is formed adjacent tothe relaxed semiconductor layer and adjacent to the distal portion ofthe contact. The metal layer is simultaneously reacted with the relaxedsemiconductor layer and with the distal portion of the contact.

The silicon and germanium of the distal portion of the contact can havean atomic density ratio that is substantially the same as an atomicdensity ratio of the silicon and germanium of the relaxed semiconductorlayer. The proximal portion of the contact can consist essentially ofsilicon or essentially of germanium. Alternatively the proximal portioncan include silicon and germanium; the atomic density ratio of thesilicon and germanium of the proximal portion can differ from the atomicdensity ratio of the silicon and germanium of the distal portion.

In a second aspect, the invention features a semiconductor device. Thedevice includes a substrate that has a reacted conductive layer thatcomprises silicon, germanium and a metallic material. The metallicmaterial can be, e.g., titanium, nickel or cobalt. The device alsoincludes a contact that has a portion proximal to the substrate and areacted conductive portion distal to the substrate. The reactedconductive distal portion of the contact includes silicon, germanium andthe same metallic material as in the substrate reacted conductive layer.The substrate can further include a strained semiconductor layer, forexample, of silicon, adjacent to the contact.

In a third aspect, the invention features a semiconductor device thatincludes a substrate that has a reacted conductive layer comprising afirst material, a second material and a metallic material. The deviceincludes a contact having a portion proximal to the substrate and areacted conductive portion distal to the substrate, the distal portioncomprising the first material, the second material and the metallicmaterial.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the sameparts throughout the different views. Also, the drawings are notnecessarily to scale, emphasis instead generally being placed uponillustrating the principles of the invention.

FIG. 1 is a cross-sectional view of a conventional silicon-based MOSFET.

FIG. 2 is a cross-sectional view of an embodiment of a MOSFET thatincludes a strained-silicon channel layer on a SiGe layer.

FIG. 3 is a graph of sheet resistance versus anneal time.

FIG. 4 is a graph of sheet resistance versus anneal temperature.

FIG. 5 is a flowchart of an embodiment of a method of fabricating asemiconductor device.

FIG. 6 is a cross-sectional view of an embodiment of a substrate usedfor fabrication of an embodiment of a MOSFET.

FIGS. 7A and 7B are cross-sectional views of structures at intermediatesteps during fabrication of an embodiment of a MOSFET, utilizing thesubstrate of FIG. 6.

FIGS. 8A and 8B are cross-sectional views of structures at fabricationsteps that follow the steps illustrated in FIGS. 7A and 7B.

DESCRIPTION

Various features of the invention are well suited to application inmetal-oxide-semiconductor (MOS) transistors having Si, Si_(1−x)Ge_(x)and/or Ge layers in and or on a substrate. The invention provides meansto avoid separation of metal layer reaction with the substrate and metallayer reaction with a polycrystalline silicon portion of a gate contact.The invention further provides improved gate design in conjunction withthe advantages of a substrate that includes a SiGe layer, among otheradvantages.

The term “MOS” is here used to refer generally to semiconductor devicesthat include a conductive gate spaced at least by an insulting layerfrom a semiconducting channel layer. The terms “SiGe” and“Si_(1−x)Ge_(x)” are here used interchangeably to refer tosilicon-germanium alloys. The term “silicide” is here used to refer to areaction product of a metal, silicon, and optionally other components,such as germanium. The term “silicide” is also used, less formally, torefer to the reaction product of a metal with an elementalsemiconductor, a compound semiconductor or an alloy semiconductor.

First, with reference to FIG. 1, to provide a context for description offeatures of the invention, the structure and operation of a conventionalMOSFET are described. FIG. 1 is cross-sectional view of a conventionalsilicon-based MOS field-effect transistor (MOSFET) 100. The transistor100 includes a gate contact 120, a pair of spacers 150, a source 135, asource silicide contact 130, a gate oxide 126, a drain 145, a drainsilicide contact 140 and a silicon substrate 110. The transistor 100 iselectrically isolated from neighboring transistors by a shallow trenchisolation (STI) portion 170.

The gate contact 120 includes a doped, conductive polycrystallinesilicon (“polysilicon”) portion 124 proximal to the gate oxide 126 and adistal gate silicide portion 122. The source 135 and drain 145 includedoped regions formed by implantation of dopant species into thesubstrate 110 and annealing, with the spacers 150 controlling thedistribution of dopant beneath the gate oxide 126. The silicide contacts130, 140 and gate silicide portion 122 provide good ohmic interfacesrespectively to the source 135 and drain 145 and to the gate polysiliconportion 124.

The MOSFET 100 has a surface channel, which may be defined in physicalor electrical terms. Physically, the surface channel is the p-type orn-type silicon that is adjacent to (i.e., below) the gate oxide 126 andwhich joins the source 135 and drain 145. Electrically, the channel isan inversion layer, which provides current flow between the source 135and drain 145. Thus, from the electrical point of view, the presence andcondition of the channel are variable.

FIG. 2 is a cross-sectional view of an embodiment of a MOSFET 200, whichis distinguished from the MOSFET 100 of FIG. 1 by the inclusion of astrained-silicon channel layer on a SiGe layer. The followingdescription of the structure of the MOSFET 200 is limited to featuresthat are substantially different from features of the conventionalMOSFET 100.

The MOSFET 200 includes a strained-silicon layer 220, a source 245, adrain 255, a source contact 240, a drain contact 250 and a substrate 210that includes a relaxed SiGe layer (other embodiments include astrained-SiGe layer). The silicon layer 220 can be epitaxially grown onthe substrate 210, and provides a surface channel for the MOSFET 200.The source and drain contacts 240, 250 can be formed by reacting a metallayer with portions of the substrate 210 and the silicon layer 220. Thesource 245 and the drain 255 can be formed by diffusing a dopant intothe substrate 210 silicon layer 220. The source and drain contacts 240,250 can be formed by depositing a metal layer and reacting the metallayer with a portion of the substrate 210, including, at least, portionsof the silicon layer 220 and the relaxed SiGe layer.

Referring now to FIGS. 3 and 4, silicidation of silicon and SiGe arecompared. Conventional processing methods would typically decouple theformation of the source and drain contacts 240, 250 and the formation ofthe distal (upper) gate silicide portion 122 due to the differingsilicidation behavior of SiGe in the substrate 210 and the polysiliconin the gate contact with a metal layer. As described below, withreference to FIGS. 3 and 4, the silicide formation rate of silicon canbe very different from the silicide formation rate of SiGe. While FIGS.3 and 4 demonstrate differences in silicidation behavior between Si andSiGe after a single annealing step, it should be noted that silicidationprocesses can utilize multiple annealing steps, oftentimes withunreacted metal being stripped between anneals.

FIG. 3 is a graph showing two curves of the sheet resistance vs. annealtime for samples having a titanium metal layer on Si and onSi_(0.7)Ge_(0.3) during reaction at 675° C. Point A indicates atypically desired interval of anneal time, between 100-150 seconds. Atthis time, the sheet resistance of the Si sample is more twice that ofthe Si_(0.7)Ge_(0.3) sample. The sheet resistance of the Si sampleeventually drops below that of the Si_(0.7)Ge_(0.3) sample after morethan 4 minutes of annealing. This time variable annealing behaviorarises from the differing reaction rates for silicide formation for Tiwith Si and with SiGe.

FIG. 4 shows a graph of the sheet resistance vs. anneal temperature forsamples of the same material combinations as those in FIG. 3. The graphshows data taken at various time intervals, from 30 seconds to 5minutes. Curves are shown for the sheet resistance vs. temperature after2 minutes of reaction time.

Point B indicates a desirable anneal temperature of 675° C. The sheetresistance of the reacted Si sample is more twice that of the reactedSi_(0.7)Ge_(0.3) sample for anneal times of approximately 2 minutes orless, again demonstrating the difference in the silicidation rates of Siand SiGe for desirable combinations of annealing time and temperature.

One method for overcoming the differences in silicidation rates of gateand source-drain regions is to decouple the gate silicide formation fromthe source-drain silicidation, as described in U.S. Pat. No. 4,755,478.The decoupled process for siliciding the source-drain regions and gateelectrode regions of a SiGe substrate typically requires more processingsteps due to separation of silicidation of polysilicon in a gate contactand silicidation of the source-drain contacts, each set of steps havingdifferent optimized conditions. Decoupling tends to increase the costsof the overall silicidation process.

The silicidation of Si can occur at a much higher temperature thansilicidation of SiGe. Therefore, an optimized silicidation processinvolving a polysilicon gate can make the SiGe substrate layervulnerable to, for example, interdiffusion, dislocation redistributionand silicide agglomeration. Features of the invention can remove a needfor decoupling, and provide gate contacts and source/drain contacts withsimilar, optimized processing conditions. The invention can furtherprovide processing at lower temperatures.

FIG. 5 is a flow diagram of an embodiment of a method 500 forfabricating a semiconductor device, according to principles of theinvention. Fabrication can begin with provision of a silicon wafer (Step510). A relaxed layer is provided (Step 520), and includes first andsecond materials, for example, silicon and germanium. For example, asubstrate that includes a relaxed layer of SiGe, intermediate layers ofSiGe and a silicon wafer can be provided; see, e.g., commonly assignedU.S. Pat. No. 6,107,653 to Fitzgerald.

A channel layer, for example, of silicon, can be provided adjacent tothe relaxed layer (Step 530). For example, a surface channel siliconlayer can be epitaxially grown on a SiGe relaxed layer. In someembodiments, a buried channel layer is provided adjacent to the relaxedlayer. Some of these embodiments include one or more buried channellayers and a surface channel layer. The channel layers can include, forexample Si, Ge or SiGe. The composition of a channel layer can be chosenin cooperation with the composition of a relaxed layer to provide adesired level of strain in the channel layer, as is conventional in theart.

The method 500 further includes formation of a contact adjacent to therelaxed layer (Step 550). The contact includes a portion that isproximal to the relaxed semiconductor layer and a portion that is distalto the relaxed semiconductor layer, i.e., lower and upper portions. Thedistal portion includes the first material and the second material, andpreferably has substantially the same composition as the relaxedsemiconductor layer. Similar compositions, for example, of SiGe, in therelaxed layer and in the upper portion of the contact enable similaroptimized processing conditions for reaction of a metal layer with therelaxed layer and with the upper portion of the contact. Thus, reactionof a metal layer can proceed simultaneously for the substrate and forthe contact.

Formation of the contact can commence with formation of a lower portionthat includes Si, Ge or SiGe (Step 540). The distal portion can then beformed from SiGe having a different composition than the semiconductorof the proximal portion. The composition can vary abruptly or smoothlywith position in the contact through the proximal and the distalportions. Thus, the composition of the proximal portion can be chosen,for example, for its electrical performance or compatibility with anadjacent gate dielectric, as described in below. The composition of thedistal portion, in contrast, can be chosen to provide compatibility withthe composition of the relaxed layer.

The method 500 further includes formation of a metal layer adjacent tothe relaxed semiconductor layer and the distal portion of the contact(Step 560). The metal can include, for example, titanium, cobalt,nickel, platinum, molybdenum, tungsten and/or zirconium. The metal layeris simultaneously reacted with the substrate and with the distal portionof the contact (Step 570). In preferred embodiments, most of the metallayer that reacts with the substrate will react with the relaxedsemiconductor layer, in part because any surface layers will berelatively thin. Thus, in these embodiments, the relaxed layer willdominate over other portions of the substrate in the reaction with themetal layer.

In the case of a substrate that includes a SiGe relaxed semiconductorlayer, the above-described method permits the formation of source anddrain silicide contacts in a substrate at the same time as formation ofa distal germanium silicide portion of a gate contact. Both gatesilicide and source and drain silicide can be formed under preferredtime and temperature annealing conditions. Thus, rather than decouplingthe formation of a conductive cap for the gate contact and formation ofsource and drain contacts, the invention facilitates simultaneousprocessing.

Various preferred embodiments of the invention utilize a substrate thatincludes a SiGe layer. The SiGe layer can be grown on a silicon wafer,and can include more than one layer of alloys of varying composition,thickness and growth conditions. Thus, the substrate can include a SiGelayer or multiple SiGe layers and/or SiGe layers having gradedcomposition. In some embodiments, the SiGe layer includes a relaxed SiGelayer grown on intermediate SiGe layers that accommodate the latticemismatch with a silicon wafer.

The substrate can include, for example, a silicon wafer, with the SiGelayers grown on the silicon wafer. In this case, an oxide layer can bepresent between the silicon wafer and the SiGe layer. Other types ofwafers can be used as a base for a substrate, e.g., silicon-on-insulator(SOI) wafers, germanium wafers, glass substrates and laminatedsubstrates.

A channel layer can be a surface or a buried layer, and can be formed,for example, from silicon, germanium or a combination of silicon andgermanium. For example, a buried channel layer can be a strained siliconlayer epitaxially grown on a relaxed SiGe layer. Alternatively, theburied layer, can be germanium or can be SiGe having a composition thatis different from the SiGe of the relaxed layer.

For example, the buried channel layer can have a composition ofSi_(1−x)Ge_(x) while the relaxed layer has a composition ofSi_(1−y)Ge_(y). For x>y, the buried SiGe layer is under compressivestress, and thus exhibits a compressive strain. Thus, materialcombinations can be chosen to provide a p-channel MOSFET, preferably byproviding a compressively strained SiGe buried layer, or an n-channelMOSFET, preferable by providing a tensilely strained silicon layer.

Some preferred embodiments of the invention use relaxed SiGe layersgrown on silicon substrates. Silicon, germanium and SiGe layers can begrown via known epitaxial growth techniques. Growth of a buried layer ofsilicon, germanium or SiGe on a SiGe relaxed layer, or SiGe on silicon,enables production of buried layers of controlled stress and dislocationdensity. Examples of SiGe substrates, in which the Ge content can be upto 100%, include: a relaxed, uniform composition SiGe layer on a gradedcomposition SiGe layer atop a Si substrate; a relaxed, uniformcomposition SiGe layer directly adjacent to a Si substrate; and arelaxed, uniform composition SiGe layer on an insulating layer likeSiO₂, adjacent a Si substrate.

Referring now to FIGS. 6-8, steps in an embodiment of a MOSFETfabrication process, and some preferred device structures, aredescribed. FIGS. 6-8 are chronologically arranged cross-sectional viewsof MOSFET-related structures at various stages of an embodiment of aMOSFET fabrication process. The completed embodiment of a MOSFET 900 isshown in FIG. 8B.

FIG. 6 illustrates an embodiment of a substrate 600 used as a base forfabrication of the embodiment of the MOSFET 900. The substrate 600includes a relaxed SiGe layer 610 and a strained Si surface layer 640.The substrate 600 can provide a base for the fabrication ofsemiconductor devices, such as transistors. The substrate 600 can bemanufactured via epitaxial growth and polishing techniques, as describedin commonly assigned U.S. Pat. No. 6,107,653 to Fitzgerald.

It will be appreciated by those skilled in the art that the relaxed SiGesubstrate layer 610 can form the base substrate of many types of MOSFETdevices. The thin strained Si layer 640 can alternatively be a SiGelayer, a sequence of Si and SiGe layers, or other combination of thinepitaxial layers, as described above.

FIGS. 7A-B illustrate some fabrication steps of a gate contact for theMOSFET 900. FIG. 7A shows a cross-sectional view of a device at a stageof fabrication, chronologically following the stage of FIG. 6. At thisstage, regions of isolation portions 730 have been formed in thesubstrate 600 to provide a modified substrate 600 a. A dielectric layer710 and a polycrystalline semiconductor layer 720 have been formed onthe substrate 600 a. The polycrystalline semiconductor layer 720 caninclude silicon and germanium.

The isolation portion 730 preferably is deep enough to cross all channellayers of semiconductor material in the substrate 600 a, ending at leastin the SiGe relaxed layer of the substrate 600 a. In other embodiments,the isolation portions 730 are absent or replaced by other isolationmeans. For example, one embodiment includes semi-recessed oxideisolation (S-ROX) portions. Generally, a relatively high degree ofplanarity is preferably maintained between the upper surface of thesubstrate 600 a and the upper surface of the isolation portions 730.

The dielectric layer 710, which provides a gate dielectric, is formed onthe exposed surface of the substrate 600, possibly consuming a portionof the surface of the strained-silicon layer 640. The dielectric layer710 can be formed by various methods conventional in the art, e.g., viathermal oxidation of the surface of the substrate 600 or via adeposition technique.

The dielectric layer 710 can be, for example, a 15-100 Å (1.5-10.0 nm)thick layer of silicon dioxide. Other embodiments include other suitabledielectric materials, e.g., silicon oxynitride, silicon nitride, aplurality of silicon nitride and silicon oxide layers, or a high-kdielectric.

A polycrystalline semiconductor layer 720 is then deposited on thedielectric layer 710, e.g., via chemical-vapor deposition. Thepolycrystalline semiconductor layer 720 can be, for example, 1000 Å (100nm) thick.

The polycrystalline semiconductor layer 720 preferably has an upperportion including SiGe with a Ge content substantially identical to theGe content of the relaxed SiGe layer 610. In some embodiments, aproximal (lower) portion of the layer 720 has a different compositionfrom that of the distal (upper) portion of the layer 720. Thus, thecomposition of the distal portion can be matched to the substrate layer610, while the portion in contact with the dielectric layer 710 can havea composition chosen, for example, for its compatibility with thedielectric material. For example, polycrystalline silicon is highlycompatible with silicon dioxide dielectric, the interface between thesetwo materials has a relatively very low electrical defect density.

FIG. 7B illustrates another stage in the production of the MOSFET 900,related to some steps in the formation of a gate contact. The dielectriclayer 710 and the polycrystalline semiconductor layer 720 have beenpatterned to respectively form a gate dielectric 710 a and a gatecontact semiconductor portion 720 a. The patterning can be performed viamethods conventional in the art, e.g., via photolithography and sputteretching.

Contact sidewall spacers 740 have been formed prior to formation of asource region 750, and a drain region 760. The sidewall spacers 740 canprovide isolation between the gate contact and source/drain regions 750,760, and facilitate fabrication of self-aligned structures. The spacers740 can be formed via methods conventional in the art, e.g., via oxidedeposition, thermal oxidation of polysilicon and/or nitride deposition.

The source region 750 and the drain region 760 include dopant, whichextends across the interface between the silicon surface layer 640 andthe SiGe relaxed layer in the further modified substrate 600 b.

For one embodiment of the MOSFET 900, the structures illustrated in FIG.7B are fabricated as follows. A layer of photosensitive polymer (e.g., aNovolak-based photoresist, as known to one having ordinary skill in thesemiconductor lithography arts) is coated on a polycrystalline-SiGesemiconductor layer 720. The polymer is exposed and developed to definea photo-mask having substantially vertical sidewalls. The exposedportions of SiGe semiconductor layer 720 are sequentially etched in adirectional mode to define the gate contact semiconductor portion 720 a.The photo-mask is removed, e.g., via an O₂ plasma etch.

The sidewall spacers 740 are formed on the exposed sides of the gatecontact semiconductor portion 720 a. The sidewall spacers 740 can beformed using one of several known methods. A preferred method is todeposit a layer of chemically vapor-deposited (CVD) oxide over theentire structure, and directionally etch the deposited layer so that itis removed from the horizontal surfaces of the substrate. During thisremoval step, exposed portions of the underlying dielectric layer 710are also removed to define the gate dielectric 710 a.

After the sidewall spacers 740 are formed, the source region 750 and thedrain region 760 are defined, for example, through ion implantation anddrive-in anneal. The diffusion regions can be formed using one ofseveral techniques. For example, implantation of dopant ions to definethe diffusion regions can use the gate contact and isolation regions 730as an implantation mask.

FIG. 8A-B illustrate aspects of silicide formation for the MOSFET 900.FIG. 8A illustrates deposition of a metal layer 820 on the structuresillustrated in FIG. 7B. The metal layer 820 is formed during a singledeposition step, and is adjacent to portions of both the substrate 600 band the gate contact semiconductor portion 720 a. The metal layer 820preferably is approximately 8-20 nanometers (nm) in thickness.

FIG. 8B is a cross-sectional view of the completed embodiment of theMOSFET 900. Upon annealing of the structures shown in FIG. 8A, andremoval of residual portions of the metal layer 820, self-aligned gateand source-drain silicide contacts are formed, as described below; theMOSFET 900 includes a gate contact silicide 920, source contact silicide950 and a drain contact silicide 960.

The gate contact silicide 920 forms from reaction of a portion of themetal layer 820 with SiGe in the gate contact semiconductor portion 720a. The source and drain contacts 950, 960 form from reaction of aportion of the metal layer 820 with Si and SiGe in the substrate 600 b,thus leaving a further modified substrate 600 c. The metal layer 820reacts with SiGe having similar or identical compositions in both thegate contact and in the substrate 600 b, providing common silicidationbehavior and silicide formation in a single step.

After reaction of the metal layer 820 with neighboring material, anunreacted gate semiconductor portion 720 b can remain in the contact.Some metals that can be used in the metal layer 820 are described in thefollowing:

-   Titanium—can provide a good silicide on SiGe, but generally not well    suited to short gate length polysilicon gates.-   Cobalt—generally preferable relative to Ti for sub-quarter    micrometer linewidths, but can lead to agglomeration problems in    conjunction with SiGe having a Ge atomic fraction of greater than    approximately 15%.-   Nickel—generally works well with SiGe, at least for Ge atomic    compositions of up to 45-50% or more, and consumes less silicon    during silicidation than some other metals.-   Platinum—generally works well with SiGe, at least for Ge atomic    compositions of up to 45-50% or more.-   Zirconium—can be used with SiGe.-   Multilayered metals—stacked metal layers (e.g., Pt/Ni) can be used.-   Alloys—can be used (e.g., NiPt).

In one embodiment of the MOSFET 900, the gate contact semiconductorportion 720 a includes SiGe with a graded composition. In thisembodiment, a distal portion of the gate contact semiconductor portion720 a has a composition that matches the relaxed SiGe layer 610, and aproximal portion, adjacent to the gate dielectric 710 a, that has agreater Ge content. The greater Ge content can be substantially pure Ge.This embodiment provides single-step silicidation of source, drain andgate with the further advantage of an improved work function due to theelevated Ge content at the interface with the gate dielectric 710 a.

In another embodiment, a proximal portion of the gate contactsemiconductor portion 720 a is substantially pure silicon. Thisembodiment provides single-step silicidation of source, drain and gate,as well as a high quality gate contact/gate oxide interface, for examplewhen the gate oxide 710 a is a silicon dioxide. It can also provide, forexample, a gate contact work function that is similar/identical toconventional MOSFETS.

Variations, modifications, and other implementations of what isdescribed herein will occur to those of ordinary skill in the artwithout departing from the spirit and the scope of the invention asclaimed. Accordingly, the invention is to be defined not by thepreceding illustrative description but instead by the spirit and scopeof the following claims.

What is claimed is:
 1. A method comprising: forming a strained layerover a relaxed layer; forming a gate dielectric layer over a portion ofthe strained layer, the gate dielectric layer defining a strainedchannel region in the strained layer; forming a source contact and adrain contact proximate the strained channel region comprising:depositing a metallic material; and performing a first annealing step,each of the source contact and drain contact comprising a reactedconductive silicide layer, the reacted conductive silicide layercomprising portion of the strained layer and the metallic material; andforming a gate contact over at least a portion of the gate dielectriclayer comprising: depositing the metallic material; and performing asecond annealing step, the gate contact including a reacted conductivesilicide portion comprising a semiconductor material and the metallicmaterial.
 2. The method of claim 1, wherein the gate contact have aproximal portion proximate the gate dielectric layer and a distalportion distal from the gate dielectric layer, the distal portion havinga material composition different from the proximal portion.
 3. Themethod of claim 2, wherein the gate contact is formed with a gradedcomposition from the proximal portion to the distal portion.
 4. Themethod of claim 3, wherein the composition of the distal portion is thesame as a composition of the relaxed layer.
 5. The method of claim 1,wherein the first annealing step and the second annealing step areperformed simultaneously.
 6. The method of claim 1, wherein thesemiconductor material of the gate contact comprises silicon andgermanium.
 7. The method of claim 1, wherein the metallic materialcomprises titanium, cobalt, nickel, platinum, molybdenum, tungsten,and/or zirconium.
 8. A device comprising: a substrate comprising astrained layer over a relaxed layer; and a gate stack over thesubstrate, the gate stack comprising a gate electrode over a dielectriclayer, the gate electrode comprising a first portion comprising a firstmaterial and a second portion comprising the first material, a secondmaterial, and a metal reacted with the first material and the secondmaterial, the first portion being disposed between the second portionand the dielectric layer, a composition of the first material betweenthe first portion and the second portion being graded.
 9. The device ofclaim 8, wherein the first portion of the gate electrode is unreactedwith the metal.
 10. The device of claim 8 further comprising: a firstsource/drain region and a second source/drain region in the substrate,the strained layer having a strained channel region defined by the gatestack, the strained channel region being disposed between the firstsource/drain region and the second source/drain region.
 11. The deviceof claim 10, wherein the first source/drain region and the secondsource/drain region are disposed at least partially in the strainedlayer.
 12. The device of claim 10, wherein each of the firstsource/drain region and the second source/drain region comprise a metalreacted with a portion of the strained layer.
 13. The device of claim10, wherein the strained layer comprises the first material, the relaxedlayer comprising the first material and the second material, the firstsource/drain region and the second source/drain region being disposed inthe strained layer and the relaxed layer, each of the first source/drainregion and the second source/drain region comprising the metal reactedwith the first material in the strained layer and reacted with the firstmaterial and the second material in the relaxed layer.
 14. The device ofclaim 13, wherein the strained layer further comprises the secondmaterial in a different percentage than the second material in therelaxed layer, each of the first source/drain region and the secondsource/drain region further comprising the metal reacted with the secondmaterial in the strained layer.
 15. The device of claim 8, wherein thefirst material is silicon and the second material is germanium.
 16. Thedevice of claim 8, wherein the graded composition of the first materialbetween the first portion and the second portion has a smooth variation.17. The device of claim 8, wherein the graded composition of the firstmaterial between the first portion and the second portion has an abruptvariation.
 18. The device of claim 8, wherein the metal comprisestitanium, cobalt, nickel, platinum, molybdenum, tungsten, and/orzirconium.
 19. A structure comprising: a strained layer over a relaxedlayer; a dielectric layer over the strained layer; a first reactedconductive silicide layer in the strained layer and the relaxed layer,the first reacted conductive silicide layer comprising a first material,a second material, and a metal reacted with the first material and thesecond material; and a gate contact over the dielectric layer, the gatecontact comprising a second reacted conductive silicide layer, thesecond reacted conductive silicide layer comprising the first material,the second material, and the metal reacted with the first material andthe second material.
 20. The structure of claim 19 wherein the gatecontact comprises an unreacted portion, the unreacted portion comprisingthe first material and the second material.